RP/IS-994/994RPDANOTICEInquire with governing authorities for local installation requirements NOTICEFor Australia and New Zealand: Pipeline strainers should be installed between the upstream shutoff valve and the inlet of the backflow preventer. 994 Installation, Maintenance, & Repair Series 994/994RPDAReduced Pressure Zone Assemblies Reduced Pressure Detector Assemblies Sizes: 2 1 ⁄ 2" – 10" (65 – 250mm) Local building or plumbing codes may require modifications to the information provided. Y ou are required to consult the local building and plumbing codes prior to installation. If this information is not consistent with local building or plumbing codes, the local codes should be fol- lowed. Need for Periodic Inspection/Maintenance: This produc t must be tested periodically in compliance with local codes, but at least once per year or more as service conditions warr ant. Corrosive water condit ions, and/or unauthorized adjustments or repair could render the product ineffective for the service intended. Regular checking and cleaning of the product’s internal components helps assure maximum life and proper product function. WARNING ! Read this Manual BEFORE using this equipment. Failure to read and follow all safety and use information can result in death, serious personal injury, property damage, or damage to the equipment. Keep this Manual for future reference. Testing For field testing procedure, refer to Watts installation sheets IS-TK-DP/DL, IS-TK-9A, IS-TK-99E and IS-TK-99D found on www.watts.com. For troubleshooting guide, refer to literature S-TSG. For other repair kits and service parts, refer to our Backflow Preven- tion Products Repair Kits & Service Parts price list PL-RP-BPD found on www.watts.com. For technical assistance, contact your local Watts representative.
Transcript
8/8/2019 Series 994/994RPDA Installation Instructions
Local building or plumbing codes may require modifications to theinformation provided. You are required to consult the local building andplumbing codes prior to installation. If this information is not consistent
with local building or plumbing codes, the local codes should be fol-lowed.
Need for Periodic Inspection/Maintenance: This product must betested periodically in compliance with local codes, but at least once peryear or more as service conditions warrant. Corrosive water conditions,and/or unauthorized adjustments or repair could render the productineffective for the service intended. Regular checking and cleaning of theproduct’s internal components helps assure maximum life and properproduct function.
WARNING!
Read this Manual BEFORE using this equipment.
Failure to read and follow all safety and use informationcan result in death, serious personal injury, propertydamage, or damage to the equipment.
Keep this Manual for future reference.
Testing
For field testing procedure, refer to Watts installation sheetsIS-TK-DP/DL, IS-TK-9A, IS-TK-99E and IS-TK-99D found onwww.watts.com.
For troubleshooting guide, refer to literature S-TSG.
For other repair kits and service parts, refer to our Backflow Preven-tion Products Repair Kits & Service Parts price list PL-RP-BPDfound on www.watts.com.
For technical assistance, contact your local Watts representative.
8/8/2019 Series 994/994RPDA Installation Instructions
1. Backflow preventers must be installed in high-visibility locations inorder to allow for immediate notice of telltale discharge or othermalfunction. This location should also facilitate testing and servic-ing and protect against freezing and vandalism.
2. Installation procedures must comply with all state and localcodes.
3. Installing a backflow preventer in a pit or vault is not recommend-
ed. An air gap below the relief port must be maintained so as toavoid flooding and submersion of the assembly, which may leadto a cross-connection. Watts recommends installations indoorsor above ground in an insulated enclosure. (Refer to literatureES-WB)
4. A strainer should be installed ahead of the backflow preventer toprotect the discs from unnecessary fouling.
CAUTION!
Do not install a strainer ahead of the backflow preventer onseldom-used, emergency water lines (i.e. fire sprinkler lines). Thestrainer mesh could potentially become clogged with debris pres-ent in the water and cause water blockage during an emergency.
5. Normal discharge and nuisance spitting are accommodated bythe use of a Watts air gap fitting and a fabricated indirect waste
line. Floor drains of the same size MUST be provided in case ofexcessive discharge.
6. When a Series 994 backflow preventer is installed for dead-endservice applications, discharge from the relief vent may occurdue to water supply pressure fluctuation during static no-flowconditions. A check valve may be required ahead of the backflowpreventer.
7. ASSEMBLY: If the backflow preventer is disassembled duringinstallation, it MUST be reassembled in its proper order. The gatevalve with the test cock is to mounted on the inlet side of thebackflow preventer. The test cock must be on the inlet side of thewedge. Failure to reassemble correctly will result in possible waterdamage due to excessive discharge from the relief port/vent andpossible malfunction of the backflow preventer.
8. Prior to installation, thoroughly flush pipe line to remove any for-eign matter.
9. START UP at Initial Installations and After Servicing: The down-stream shutoff should be closed. Slowly open upstream shutoffand allow the backflow preventer to fill slowly. Bleed air at eachtest cock. When backflow preventer is filled, slowly open thedownstream shutoff and fill the water supply system. This is nec-essary to avoid water hammer or shock damage.
NOTICE
Assembly body should not be painted.
Figure 1
VALVE SIZE
TYPICAL FLOW RATES AS
SIZED BY FLOOR DRAIN
MANUFACTURERS
DRAIN SIZE
in. mm
21 ⁄ 2 65 55 gpm 23 80 112 gpm 34 100 170 gpm 4
6, 8, 10 150, 200, 250 350 gpm 5
Basic Installation InstructionsSeries 994 Reduced Pressure Zone Assemblies
#2 Test Cock
#3 Test Cock
#4 Test Cock
OutletShutoff
#2 Check
Relief
Valve
SensingLine
1st Check
#1 Test Cock
Inlet Shutoff Valve
NOTICE
The flange gasket bolts for the gate valves should be re tightened duringinstallation as the bolts may have loosened due to storage and shipping.
8/8/2019 Series 994/994RPDA Installation Instructions
*For additional information on Watts insulated enclosures refer to literature ES-WB.
ParallelIndoors
Above Ground
12” (300mm) min.Refer to
Local Codes
Strainer
12” (300mm) min.Refer to
Local Codes
12” (300mm) min.Refer to Local Codes
*Insulated Enclosure
Installation
A. Series 994 shall be installed in a horizontal position. The shutoffvalve with the test cock is to be mounted on the inlet side of thebackflow preventer. The test cock is on the inlet side of the shut-off valve.
B. The 994 should always be installed in an accessible location tofacilitate testing and servicing. Check the state and local codesto ensure that the backflow preventer is installed in compliance,such as the proper height above the ground. The backflow pre-venter must be supported and is not designed to carry full weightof the stand pipe.
C. Water discharge from the relief valve should be vented in accor-dance with code requirements. The relief valve should never besolidly piped into a drainage ditch, sewer or sump. The dischargeshould be funneled through a Watts air gap fitting piped to a floordrain.
D. Watts recommends a strainer be installed ahead of Watts Series994 assemblies to protect the discs from unnecessary fouling.
CAUTION!
Do not install a strainer ahead of the backflow preventer onseldom-used, emergency water lines (i.e. fire sprinkler lines). Thestrainer mesh could potentially become clogged with debris pres-ent in the water and cause water blockage during an emergency.
Start Up
E. The downstream shutoff should be closed. Open upstream slow-ly, fill the valve and bleed the air through Test cock 2, 3 and 4.When valve is filled, open the downstream shutoff slowly and fillthe water supply system. This is necessary to avoid water ham-mer or shock damage.
F. The installation of a Watts air gap with the drain line terminatingabove a floor drain will handle any normal discharge or nuisancespitting through the relief valve. However, floor drain size mayneed to be designed to prevent water damage caused by a cata-strophic failure condition. Do not reduce the size of the drain line
from the air gap fitting.
G. Two or more smaller size valves can be piped in parallel (whenapproved) to serve a large supply pipe main. This type of installa-tion is employed where increase capacity is needed beyond thatprovided by a single valve and permits testing or servicing of anindividual valve without shutting down the complete line.
The number of assemblies used in parallel should be determinedby the engineer’s judgement based on the operating conditionsof a specific installation.
994
994
994
8/8/2019 Series 994/994RPDA Installation Instructions
Servicing First and Second ChecksSeries 994/994RPDA 4" and 6" (100 – 150mm)
Removing Check Assemblies (Before servicingbe sure shutoff valves are closed)
Figure 3
Figure 2
Figure 4
B
A
C
Screwdriver
#2 Check#1 Check
#1 Check 21 ⁄ 2" – 6" (65 – 150mm)
Spring
Cam Arm
Roller
ClapperSeat
O-ring Seal &Groove
#2 Check
Spring
Cam Arm
Roller
6” Only
Clapper
O-ring Seal & Groove
Seat
Lug
O-ring Seal & Groove
Figure 5A
6" (150mm)2nd Check RP
Valve Outlet Flange ThreadedStud on Flange
Cam Bar Open Pin
Figure 5B
Cleaning Position
1. Slowly open all ball valves to relieve air and water pressure.Loosen bolts on groove coupler and remove groove couple
and cover plate from valve body.2. Remove #1 Check Assembly by using your hands to unscrew
(turn counterclockwise) Check and remove through top accessport. Do not use Check Arm as a handle to unscrew. If Checkcannot be loosened by hand, insert a long screwdriver betweenvalve body and Check (see figure 2). Gently apply pressureagainst the Check until loosened. Finish unscrewing by hand. Un-screw #2 Check (turn counter-clockwise) by placing along screw-driver across lugs and applying pressure to loosen #2 Check.Finish unscrewing by hand.
3. To clean #1 Check 6" (150mm) only, locate the Check Armopening stud on the outlet flange of the valve assembly. Slide theCheck Arm over the stud with the check threads facing down-ward (figure 5A). Tighten 1 / 4" (8mm) nut on stud to secure cambar. Slowly pull the assembly outward to open check allowing ex-posure of the seat clapper area for cleaning. To clean #2 Check,
lift Cam Arm and hold in open position. Raise clapper so that theend of the Check Arm rests between roller and clapper (figure5B). Thoroughly clean the seat area and clapper sealing surfacesof both Checks. Inspect seats, clapper sealing surfaces, Check
Arms, and O-rings for damage, nicks, and debris. If not dam-aged, gently close the clapper. If damaged, install a new Checkassembly and/or O-ring.
4. Before reinstallation of Checks, thoroughly clean O-ring grooveand lubricate O-ring with FDA approved lubricant. Insert andthread #2 Check first and then #1 Check. #2 Check should betightened by inserting a long screwdriver between lugs to tightenfirmly (see figure 2). Do not over tighten. Tighten #1 Check firmlyby hand only. Replace cover plate, clean groove coupler gasketand groove. Replace groove coupler. Repres-surize and bleed airfrom all test cocks.
Figure 17
Note: See page 6 for additional 1st check servicing
8/8/2019 Series 994/994RPDA Installation Instructions
Servicing First andSecond ChecksSeries 994/994RPDA8" and 10" (200 – 250mm)
1. Slowly open all ball valves to relieve air and water pressure.Loosen bolts on groove coupler and remove groove couple andcover plate from valve body.
2. #1 CHECK
Using a 9 ⁄ 16" socket wrench or nut driver, remove the four nutsfrom the #1 check studs (see fig. 1). Using two hands, placethem at 12 o’clock and 6 o’clock, wiggle the check assembly free.Remove through access port with back of clapper first with springend down. Pull check assembly out of main body. Inspect seatsand clapper sealing surfaces. (See page 6.)
#2 CHECK
After loosening bolts with a 9 ⁄ 16" socket, remove bolts completely.Using the centerline access bar, spin the check assembly from the9 o’clock position to the 12 o’clock position, then (without letting
go of the access bar) push the cam assembly slightly downstreamso that the clapper is now parallel to the valve body. Now bringthe check assembly through the check retaining wall. Leave thecheck assembly parallel to the valve body. Pull the check assem-bly through the access port.
3. Using a 3 ⁄ 8" nut driver or a piece of small diameter pipe, placeon the check arm torsion spring and move away from and moveaway from and around the torsion spring retaining bracket so asto relieve the torsion spring tension. This will allow the check armto move freely, enabling you to inspect the clapper face and checkseat. Thoroughly clean the seat area and clapper sealing surfaces,check arms, and O-rings for damage, nicks, and debris. If dam-aged, install a new check assembly and or O-ring.
4. Before reinstallation of check assembly, thoroughly clean O-ringgroove and lubricate O-ring with F.D.A. approved lubricant.
Figure 1
Check Studs
Check Studs
Figure 3
#2 Cam-Check DC & RP
Figure 2
#1 Cam-Check RP
Figure 4
Removing Check Assemblies (Before servicing
be certain shutoff valves are closed)1. After removing the first check from the backflow valve body, place
on a flat surface with the coil spring facing up.
2. In order to gain access to the seat and clapper rubber ring, youmust compress the spring (#3) that surrounds the clapper shaft(#1). To do so, you must place the 3 ⁄ 8" threaded rod through twoholes of the spring retaining plate #2.
3. After placing the 3 ⁄ 8” all-thread rod through the spring retainingplate, Screw the threaded rod into the holes (#4) at the base ofspider (#5 next to shaft). Be sure to use two nuts on the threadedrod to tighten them into the holes. The depth of the threadedholes should be approximately 1 ⁄ 2". This operation will require youto use two pieces of threaded rod (see drawing below).
4. Compressing the spring. To do so you need to loosen the top 3 ⁄ 8”nut and back it off without unthreading the threaded rod from the
spider. Place a box end wrench or crescent wrench on the3
⁄ 8”nut closest to the spring retaining plate and tighten. Tighten boththreaded and nut evenly; put a few turns on one threaded rod nutand a few turns on the other.
5. During compression, the clapper will slowly move up, away fromthe seat. To examine the seat, continue spring compression untilthe clapper has moved approximately 1" from the seat. This willallow debris to be removed and or the seat to be examined.
6. To unload the spring compression, loosen the all-thread and thendouble nut the all-thread and unscrew the rod from the spider andshaft base.
1. Shaft
2. Spring retaining plate
3. Spring
4. 3 ⁄ 8” threaded hole (maintenance)
5. Spider
6. Spider retaining bolt
7. Seat ring
8. Clapper to shaft bolt
9. Seat ring retainer 1
2
3
4
5
6
3 ⁄ 8 - 16var.
Threaded Rod
7
8
9
#1 Check Valve 8" & 10"(200 & 250mm)
DANGER!
Use extreme caution when servicing the first check!
Servicing theFirst CheckTo inspect the seat and clean the seat and
clapper washer:
To disassemble the first check, you will needthe following:
• Two pieces of 3 ⁄ 8" threaded rod (approximately 14" long)
• Adjustable crescent wrench
• Pipe wrench or channel lock pliers
8/8/2019 Series 994/994RPDA Installation Instructions
Servicing the Relief Valve1. The relief valve may be serviced while on or off the backflow
preventer valve.
2. NOTICE
DO NOT USE A PIPE WRENCH TO REMOVE THE RELIEF VALVE ASSEMBLY FROM THE BACKFLOW PREVENTER.
3. Shut down water system.
Relief Valve Disassembly
1. Disconnect the relief valve hose from the elbow in the bottomflange cover at the swivel hose connection. Do not remove theelbow.
2. If the valve is to be removed from the backflow preventer forservice, place a screw driver blade or flat bar across the edgesof two of the hex head screws in the bottom flange cover andturn counter-clockwise to loosen the relief valve assembly. (SeeFigure 2 page 4)
3. Remove the four bottom bolts from the bottom of the relief valveassembly with a 5 ⁄ 16” socket or open-end wrench. Remove thebottom flange cover.
4. Remove the piston assembly & sleeve from the relief valve bodyby placing your index fingers through the slots in the side of the
body and pressing down on the top of the disc retainer in the topof the piston assembly. (See Figure 7.)
5. Pull the piston assembly free of the body by grasping the sleeveand pulling down.
6. Grip the sleeve and the piston assembly by the head of the hexhead bolt. Pull up on the sleeve to extend the diaphragm. Slidethe sleeve (item #26) completely off of the diaphragm and in-spect the diaphragm for tears, holes or excessive wrinkles. If thediaphragm is damaged, order a new piston/diaphragm assembly.
Relief Valve Reassembly
1. Thoroughly clean all inside surfaces of the relief valve body.
2. Inspect the relief valve body seat surface located at the top edge
of the three discharge slots near the top of the body by rubbingthe end of the index finger around the entire seat surface; accessthe seat surface through the slots or the bottom of the body. Theseat must be free of nicks. If nicks are discovered, remove thebody & install a new relief valve assembly.
3. Position the diaphragm on the piston assembly so that it is facingup as shown in Figure 8.
4. Now fold the top (ribbed) edge of the diaphragm inward, graspthe sleeve with the ribbed edge up and slide the sleeve downover the piston assembly as shown in Figure 8.
5. While still holding the sleeve, slide it up over the diaphragmand, using your thumb & index finger, position the bead of thediaphragm so that it wraps over the outside of the rib on the topof the sleeve so that the sleeve is held by the diaphragm. Nowplace the piston assembly on a f lat, firm surface with diaphragmfacing up as shown in Figure 9.
6. Cup your hand slightly to form an air trap and force the sleevedown over the piston assembly with a rapid slap (hard) on theopen end of the diaphragm with your cupped hand. The trappedair in the diaphragm will force the diaphragm between the insideof the sleeve and the outside of the piston. Ensure that the dia-phragm is fully seated. If diaphragm is wrinkled, repeat previousstep.
7. Slide the piston assembly and sleeve into the relief valve bodywith the hex head bolt entering the flanged end of the body first.Slide the piston assembly in until the diaphragm lip is smoothlyseated in the machined groove in the flanged end of the body.By running your index finger around the outside of the diaphragmbead, you will ensure it is seated smoothly
Item # Part Description Qty.
21 Relief Valve Body 1 22 Rubber Shutoff Disc 1 23 Piston Diaphragm Assembly 1 24 Hex Head Bolt 4 25 Disc Retainer 1 26 Sleeve 1 27 Bottom Bolt 1 28 Bottom Flange (w st. elbow) 1 29 Bottom st. elbow 1 30 O-ring disc 1
PARTS TABLE #2
Figure 6
27
21
22
23
24
25
26
28
2930
Figure 7
Figure 8
Figure 9
8. Position the bottom flange cover on the bottom of the relief valvebody and secure by hand tightening the four bottom bolts.
9. Now tighten the four bottom bolts to approximately 15 ft.-lbs.with a 5 / 16" socket or open-end wrench.
10. Reattach the relief valve hose to the elbow in the bottom flangecover.
8/8/2019 Series 994/994RPDA Installation Instructions
Testing - Reduced Pressure Zone AssembliesWatts TK-DL The following Test Procedure is one of several that is recognized
throughout the United States for testing Backflow Preventers.
The following procedure is not a specific recommendation. TheWatts series of test kits are capable of performing any of the recog-nized Backflow test procedures.
For additional testing information refer to literature IS-TK-DL, IS-TK-9A and IS-TK-99E
A. Open TC #4 and flush test cocks No’s. 1, 2 and 3 on BF assem-
bly, then close TC #4.B. Turn tester on (before connecting hoses). Tester must read all
zeros. Close VA and VB.
Test No. 1 - Relief Valve1. Install high-side hose between TC #2 and tester connection A.
2. Install low-side hose between TC #3 and tester connection B.
3. Open TC #3 then VB. Now open TC #2 slowly, then VA. Close VA then VB.
4. Close #2 shutoff valve.
5. Observe the apparent first check valve differential pressure (A - B).
6. Install bypass hose between VA and VB. Open VB and bleed airby loosening hose connection at VA. Tighten hose connectionand close VB.
Push - Print Head (wait) then Push - Start Test7. Open VA, then slowly open VB (no more than 1⁄4 turn). When
relief valve drips, push the “hold button” for 2 seconds. Recordreading (must be 2 PSID or more).Push - Stop Test
8. Close VA and VB.
Test No. 2 - Test No. 2 Check Valve9. Install bypass hose between VA and TC #4. Open VA, then
bleed air by loosening hose connection at TC #4. Tighten hoseconnection. Close VA.Push - Start Test
10. Open VB to reestablish pressure within the “zone”. Close VB.
11. Open TC #4, then open VA. If relief valve does not drip, record
second check valve as “close tight”.
Test No. 3 - Test No. 1 Check Valve12. Open VB to reestablish first check valve differential pressure.
Close VB. Record pressure differential.Stop Test (Push Stop Test twice)
13. Close test cocks and remove tester, return assembly to normaloperating condition.
RPZTest 1
RPZTest 2
RPZTest 3
Series 994
A B
VA VB
WARNING!
It is important that this device be tested periodically in compliancewith local codes, but at least once per year or more as ser vice con-ditions warrant. If installed on a fire sprinkler system all mechanicalchecks, such as alarm checks, single checks and backflow preventersshould be inspected internally every one to five years in accordancewith NFPA 13 A and NFPA 25
Series 994
Series 994
A B
VA VB
A B
VA VB
8/8/2019 Series 994/994RPDA Installation Instructions
Limited Warranty: Watts Regulator Co. (the “Company”) warrants each product to be free from defects in material and workmanship under normal usage for a period of one year from the date oforiginal shipment. In the event of such defects within the warranty period, the Company will, at its option, replace or recondition the product without charge.
THE WARRANTY SET FORTH HEREIN IS GIVEN EXPRESSLY AND IS THE ONLY WARRANTY GIVEN BY THE COMPANY WITH RESPECT TO THE PRODUCT. THE COMPANY MAKES NO OTHERWARRANTIES, EXPRESS OR IMPLIED. THE COMPANY HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.The remedy described in the first paragraph of this warranty shall constitute the sole and exclusive remedy for breach of warranty, and the Company shall not be responsible for any incidental, specialor consequential damages, including without limitation, lost profits or the cost of repairing or replacing other property which is damaged if this product does not work properly, other costs resultingfrom labor charges, delays, vandalism, negligence, fouling caused by foreign material, damage from adverse water conditions, chemical, or any other circumstances over which the Company has nocontrol. This warranty shall be invalidated by any abuse, misuse, misapplication, improper installation or improper maintenance or alteration of the product.Some States do not allow limitations on how long an implied warranty lasts, and some States do not allow the exclusion or limitation of incidental or consequential damages. Therefore the abovelimitations may not apply to you. This Limited Warranty gives you specific legal rights, and you may have other rights that vary from State to State. You should consult applicable state laws todetermine your rights. SO FAR AS IS CONSISTENT WITH APPLICABLE STATE LAW, ANY IMPLIED WARRANTIES THAT MAY NOT BE DISCLAIMED, INCLUDING THE IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL SHIPMENT.
A Watts Water Technologies Company
WARNING: This product contains chemicals known to theState of California to cause cancer and birth defects orother reproductive harm.For more information: www.watts.com/prop65
For repair kits and parts, refer to ourBackflow Prevention Products RepairKits & Service Parts price list PL-RP-BPDfound on www.watts.com.
